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Sandia Fracture Challenge 3: detailing the Sandia Team Q failure prediction strategy

International Journal of Fracture

Karlson, Kyle N.; Alleman, Coleman A.; Foulk, James W.; Manktelow, Kevin M.; Ostien, Jakob O.; Stender, Michael S.; Stershic, Andrew J.; Veilleux, Michael V.

The third Sandia Fracture Challenge highlighted the geometric and material uncertainties introduced by modern additive manufacturing techniques. Tasked with the challenge of predicting failure of a complex additively-manufactured geometry made of 316L stainless steel, we combined a rigorous material calibration scheme with a number of statistical assessments of problem uncertainties. Specifically, we used optimization techniques to calibrate a rate-dependent and anisotropic Hill plasticity model to represent material deformation coupled with a damage model driven by void growth and nucleation. Through targeted simulation studies we assessed the influence of internal voids and surface flaws on the specimens of interest in the challenge which guided our material modeling choices. Employing the Kolmogorov–Smirnov test statistic, we developed a representative suite of simulations to account for the geometric variability of test specimens and the variability introduced by material parameter uncertainty. This approach allowed the team to successfully predict the failure mode of the experimental test population as well as the global response with a high degree of accuracy.

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TYPE Journal Article YEAR 2019
ScopusOSTIDOI

Born Qualified Grand Challenge LDRD Final Report

Roach, R.A.; Argibay, Nicolas A.; Allen, Kyle M.; Balch, Dorian K.; Beghini, Lauren L.; Bishop, Joseph E.; Boyce, Brad B.; Brown, Judith A.; Burchard, Ross L.; Chandross, M.; Cook, Adam W.; DiAntonio, Christopher D.; Dressler, Amber D.; Forrest, Eric C.; Ford, Kurtis R.; Ivanoff, Thomas I.; Jared, Bradley H.; Johnson, Kyle J.; Kammler, Daniel K.; Koepke, Joshua R.; Kustas, Andrew K.; Lavin, Judith M.; Leathe, Nicholas L.; Lester, Brian T.; Madison, Jonathan D.; Mani, Seethambal S.; Martinez, Mario J.; Moser, Daniel M.; Rodgers, Theron R.; Seidl, Daniel T.; Brown-Shaklee, Harlan J.; Stanford, Joshua S.; Stender, Michael S.; Sugar, Joshua D.; Swiler, Laura P.; Taylor, Samantha T.; Trembacki, Bradley T.

This SAND report fulfills the final report requirement for the Born Qualified Grand Challenge LDRD. Born Qualified was funded from FY16-FY18 with a total budget of ~$13M over the 3 years of funding. Overall 70+ staff, Post Docs, and students supported this project over its lifetime. The driver for Born Qualified was using Additive Manufacturing (AM) to change the qualification paradigm for low volume, high value, high consequence, complex parts that are common in high-risk industries such as ND, defense, energy, aerospace, and medical. AM offers the opportunity to transform design, manufacturing, and qualification with its unique capabilities. AM is a disruptive technology, allowing the capability to simultaneously create part and material while tightly controlling and monitoring the manufacturing process at the voxel level, with the inherent flexibility and agility in printing layer-by-layer. AM enables the possibility of measuring critical material and part parameters during manufacturing, thus changing the way we collect data, assess performance, and accept or qualify parts. It provides an opportunity to shift from the current iterative design-build-test qualification paradigm using traditional manufacturing processes to design-by-predictivity where requirements are addressed concurrently and rapidly. The new qualification paradigm driven by AM provides the opportunity to predict performance probabilistically, to optimally control the manufacturing process, and to implement accelerated cycles of learning. Exploiting these capabilities to realize a new uncertainty quantification-driven qualification that is rapid, flexible, and practical is the focus of this effort.

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TYPE SAND Report YEAR 2018
OSTIDOI

Changing the Engineering Design & Qualification Paradigm in Component Design & Manufacturing (Born Qualified)

Roach, R.A.; Bishop, Joseph E.; Jared, Bradley H.; Keicher, David M.; Cook, Adam W.; Whetten, Shaun R.; Forrest, Eric C.; Stanford, Joshua S.; Boyce, Brad B.; Johnson, Kyle J.; Rodgers, Theron R.; Ford, Kurtis R.; Martinez, Mario J.; Moser, Daniel M.; van Bloemen Waanders, Bart G.; Chandross, M.; Abdeljawad, Fadi F.; Allen, Kyle M.; Stender, Michael S.; Beghini, Lauren L.; Swiler, Laura P.; Lester, Brian T.; Argibay, Nicolas A.; Brown-Shaklee, Harlan J.; Kustas, Andrew K.; Sugar, Joshua D.; Kammler, Daniel K.; Wilson, Mark A.

Abstract not provided.

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TYPE Presentation YEAR 2018
OSTI

A thermal-mechanical finite element workflow for directed energy deposition additive manufacturing process modeling

Additive Manufacturing

Stender, Michael S.; Beghini, Lauren L.; Sugar, Joshua D.; Veilleux, Michael V.; Subia, Samuel R.; Smith, Thale R.; San Marchi, Christopher W.; Brown, Arthur B.; Dagel, Daryl D.

This work proposes a finite element (FE) analysis workflow to simulate directed energy deposition (DED) additive manufacturing at a macroscopic length scale (i.e. part length scale) and to predict thermal conditions during manufacturing, as well as distortions, strength and residual stresses at the completion of manufacturing. The proposed analysis method incorporates a multi-step FE workflow to elucidate the thermal and mechanical responses in laser engineered net shaping (LENS) manufacturing. For each time step, a thermal element activation scheme captures the material deposition process. Then, activated elements and their associated geometry are analyzed first thermally for heat flow due to radiation, convection, and conduction, and then mechanically for the resulting stresses, displacements, and material property evolution. Simulations agree with experimentally measured in situ thermal measurements for simple cylindrical build geometries, as well as general trends of local hardness distribution and plastic strain accumulation (represented by relative distribution of geometrically necessary dislocations).

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TYPE Journal Article YEAR 2018
ScopusOSTIDOI

Thermal mechanical finite element simulation of additive manufacturing; process modeling of the LENS process

American Society of Mechanical Engineers, Pressure Vessels and Piping Division (Publication) PVP

Stender, Michael S.; Beghini, Lauren L.; Veilleux, Michael V.; Subia, Samuel R.; Sugar, Joshua D.

Laser engineered net shaping (LENS) is an additive manufacturing process that presents a promising method of creating or repairing metal parts not previously feasible with traditional manufacturing methods. The LENS process involves the directed deposition of metal via a laser power source and a spray of metal powder co-located to create and feed a molten pool (also referred to generically as Directed Energy Deposition, DED). DED technologies are being developed for use in prototyping, repair, and manufacturing across a wide variety of materials including stainless steel, titanium, tungsten carbidecobalt, aluminum, and nickel based superalloys. However, barriers to the successful production and qualification of LENS produced or repaired parts remain. This work proposes a finite element (FE) analysis methodology capable of simulating the LENS process at the continuum length scale (i.e. part length scale). This method incorporates an element activation scheme wherein only elements that exceed the material melt temperature during laser heating are activated and carried through to subsequent analysis steps. Following the initial element activation calculation, newly deposited, or activated elements and the associated geometry, are carried through to thermal and mechanical analyses to calculate heat flow due to radiation, convection, and conduction as well as stresses and displacements. The final aim of this work is to develop a validated LENS process simulation capability that can accurately predict temperature history, final part shape, distribution of strength, microstructural properties, and residual stresses based on LENS process parameters.

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TYPE Conference Poster YEAR 2017
ScopusOSTIDOI
42 Results
42 Results