scholarly journals Bayesian inverse uncertainty quantification of a MOOSE-based melt pool model for additive manufacturing using experimental data

2022 ◽  
Vol 165 ◽  
pp. 108782
Author(s):  
Ziyu Xie ◽  
Wen Jiang ◽  
Congjian Wang ◽  
Xu Wu
Keyword(s):  
Experimental Data ◽  
Additive Manufacturing ◽  
Uncertainty Quantification ◽  
Melt Pool ◽  
Pool Model

Uncertainty Quantification of Mesoscale Melt-Pool Model for Powder Bed Fusion Additive Manufacturing of Metals

2021 ◽  
Author(s):  
Sayan Ghosh ◽  
Andrey I. Meshkov ◽  
Vipul Gupta ◽  
Piyush Pandita ◽  
Yiming Zhang ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Uncertainty Quantification ◽  
Powder Bed Fusion ◽  
Powder Bed ◽  
Melt Pool ◽  
Pool Model

scholarly journals Uncertainty quantification and reduction in metal additive manufacturing

2020 ◽  
Vol 6 (1) ◽  
Author(s):  
Zhuo Wang ◽  
Chen Jiang ◽  
Pengwei Liu ◽  
Wenhua Yang ◽  
Ying Zhao ◽  
...  
Keyword(s):  
Quality Control ◽  
Additive Manufacturing ◽  
Computational Model ◽  
Uncertainty Quantification ◽  
High Throughput ◽  
Surrogate Model ◽  
Metal Additive Manufacturing ◽  
Uncertainty Sources ◽  
Melt Pool ◽  
Metal Additive

AbstractUncertainty quantification (UQ) in metal additive manufacturing (AM) has attracted tremendous interest in order to dramatically improve product reliability. Model-based UQ, which relies on the validity of a computational model, has been widely explored as a potential substitute for the time-consuming and expensive UQ solely based on experiments. However, its adoption in the practical AM process requires overcoming two main challenges: (1) the inaccurate knowledge of uncertainty sources and (2) the intrinsic uncertainty associated with the computational model. Here, we propose a data-driven framework to tackle these two challenges by combining high throughput physical/surrogate model simulations and the AM-Bench experimental data from the National Institute of Standards and Technology (NIST). We first construct a surrogate model, based on high throughput physical simulations, for predicting the three-dimensional (3D) melt pool geometry and its uncertainty with respect to AM parameters and uncertainty sources. We then employ a sequential Bayesian calibration method to perform experimental parameter calibration and model correction to significantly improve the validity of the 3D melt pool surrogate model. The application of the calibrated melt pool model to UQ of the porosity level, an important quality factor, of AM parts, demonstrates its potential use in AM quality control. The proposed UQ framework can be generally applicable to different AM processes, representing a significant advance toward physics-based quality control of AM products.

Stand-Alone Containment Analysis of the Phébus FPT-3 Test With the ASTEC and the MELCOR Codes

2018 ◽  
Author(s):  
Bruno Gonfiotti ◽  
Sandro Paci
Keyword(s):  
Experimental Data ◽  
Numerical Models ◽  
Research Programme ◽  
Severe Accident ◽  
Sensitivity Analyses ◽  
Correct Prediction ◽  
Control Rod ◽  
Melt Pool ◽  
Fuel Bundle ◽  
Pool Model

The Phébus FP experimental campaign (1988–2010) is recognized as one of the most relevant in the field of Severe Accident researches. During this international research programme, 4 tests were performed to investigate the degradation phenomena for a real PWR fuel bundle in strongly or weakly oxidizing conditions, considering different control rod materials and burn-up levels, plus 1 test studying the phenomena related to a melt pool scenario. These integral tests gave a fundamental improvement in the knowledge of the key phenomena occurring during a Severe Accident and the obtained data were also employed to develop numerical models for the safety analysis of these scenarios. The ASTEC and the MELCOR integral codes were two of the main international codes that have benefited from these experimental data. After the termination of the Phébus FP campaign, these two codes were furthermore improved, implementing more recent research findings. So, a continuous verification and validation work is necessary to check that the new improvements, implemented in such codes, also allow a better prediction of these past Phébus FP tests. Therefore, the aim of the present work is to re-analyze the Phébus FPT-3 test employing the up-to-date versions of the ASTEC and MELCOR codes. This FPT-3 test was also the basis for an international benchmark exercise carried out in the frame of the EU SARNET project. The performed analysis focuses only on the stand-alone containment aspects of the test, and a comparison against the results obtained by the different participants to the SARNET benchmark is also performed. An original analysis on the main differences obtained employing three different spatial nodalizations and a sensitivity analysis on the effects of different input parameters influencing the aerosol behavior are also proposed. These sensitivity analyses also show the need of a sufficient number of volumes for a correct prediction of the coupling between the containment thermal-hydraulics transient and the aerosol behavior. The results obtained show only a partial agreement with the experimental data and with the best calculations performed during the SARNET benchmark, due to user’s effects and code’s limitations as the ones present in the Iodine pool model in MELCOR.

scholarly journals Optimization of Laser Powder Bed Fusion Processing Using a Combination of Melt Pool Modeling and Design of Experiment Approaches: Density Control

2019 ◽  
Vol 3 (1) ◽  
pp. 21 ◽  
Author(s):  
Morgan Letenneur ◽  
Alena Kreitcberg ◽  
Vladimir Brailovski
Keyword(s):  
Scanning Speed ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Powder Bed ◽  
Density Prediction ◽  
Melt Pool ◽  
Density Control ◽  
Pool Model ◽  
Conventional Material ◽  
Prediction Approach

A simplified analytical model of the laser powder bed fusion (LPBF) process was used to develop a novel density prediction approach that can be adapted for any given powder feedstock and LPBF system. First, calibration coupons were built using IN625, Ti64 and Fe powders and a specific LPBF system. These coupons were manufactured using the predetermined ranges of laser power, scanning speed, hatching space, and layer thickness, and their densities were measured using conventional material characterization techniques. Next, a simplified melt pool model was used to calculate the melt pool dimensions for the selected sets of printing parameters. Both sets of data were then combined to predict the density of printed parts. This approach was additionally validated using the literature data on AlSi10Mg and 316L alloys, thus demonstrating that it can reliably be used to optimize the laser powder bed metal fusion process.

scholarly journals Additive Manufacturing of Bulk Nanocrystalline FeNdB Based Permanent Magnets

Micromachines ◽  
2021 ◽  
Vol 12 (5) ◽  
pp. 538
Author(s):  
Dagmar Goll ◽  
Felix Trauter ◽  
Timo Bernthaler ◽  
Jochen Schanz ◽  
Harald Riegel ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Melt Spinning ◽  
Permanent Magnets ◽  
Maximum Energy ◽  
Laser Melting ◽  
Powder Bed ◽  
Melt Pool ◽  
Bulk Nanocrystalline ◽  
Ribbon Structures ◽  
Nanocrystalline Ribbon

Lab scale additive manufacturing of Fe-Nd-B based powders was performed to realize bulk nanocrystalline Fe-Nd-B based permanent magnets. For fabrication a special inert gas process chamber for laser powder bed fusion was used. Inspired by the nanocrystalline ribbon structures, well-known from melt-spinning, the concept was successfully transferred to the additive manufactured parts. For example, for Nd16.5-Pr1.5-Zr2.6-Ti2.5-Co2.2-Fe65.9-B8.8 (excess rare earth (RE) = Nd, Pr; the amount of additives was chosen following Magnequench (MQ) powder composition) a maximum coercivity of µ0Hc = 1.16 T, remanence Jr = 0.58 T and maximum energy density of (BH)max = 62.3 kJ/m3 have been achieved. The most important prerequisite to develop nanocrystalline printed parts with good magnetic properties is to enable rapid solidification during selective laser melting. This is made possible by a shallow melt pool during laser melting. Melt pool depths as low as 20 to 40 µm have been achieved. The printed bulk nanocrystalline Fe-Nd-B based permanent magnets have the potential to realize magnets known so far as polymer bonded magnets without polymer.

Accelerating Large-Format Metal Additive Manufacturing: How Controls R&D Is Driving Speed, Scale, and Efficiency

2020 ◽  
Author(s):  
Brian T. Gibson ◽  
Paritosh Mhatre ◽  
Michael C. Borish ◽  
Justin L. West ◽  
Emma D. Betters ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Large Scale ◽  
Closed Loop ◽  
Size Control ◽  
Pool Size ◽  
Large Format ◽  
Layer Height ◽  
Melt Pool ◽  
The Impact ◽  
Melt Pool Size

Abstract This article highlights work at Oak Ridge National Laboratory’s Manufacturing Demonstration Facility to develop closed-loop, feedback control for laser-wire based Directed Energy Deposition, a form of metal Big Area Additive Manufacturing (m-BAAM), a process being developed in partnership with GKN Aerospace specifically for the production of Ti-6Al-4V pre-forms for aerospace components. A large-scale structural demonstrator component is presented as a case-study in which not just control, but the entire 3D printing workflow for m-BAAM is discussed in detail, including design principles for large-format metal AM, toolpath generation, parameter development, process control, and system operation, as well as post-print net-shape geometric analysis and finish machining. In terms of control, a multi-sensor approach has been utilized to measure both layer height and melt pool size, and multiple modes of closed-loop control have been developed to manipulate process parameters (laser power, print speed, deposition rate) to control these variables. Layer height control and melt pool size control have yielded excellent local (intralayer) and global (component-level) geometry control, and the impact of melt pool size control in particular on thermal gradients and material properties is the subject of continuing research. Further, these modes of control have allowed the process to advance to higher deposition rates (exceeding 7.5 lb/hr), larger parts (1-meter scale), shorter build times, and higher overall efficiency. The control modes are examined individually, highlighting their development, demonstration, and lessons learned, and it is shown how they operate concurrently to enable the printing of a large-scale, near net shape Ti-6Al-4V component.

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