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PUBLICATION NOTICE: Additive Manufacturing of Metallic Materials with Controlled Microstructures: Multiscale Modeling of Direct Metal Laser Sintering and Directed Energy Deposition

US Army Engineer Research and Development Center
Published July 24, 2019

The US Army Engineer Research and Development Center has published the report/note described and linked below. Approved for public release; distribution is unlimited.

Report Number:

ERDC TR-19-9

Title:

Additive Manufacturing of Metallic Materials with Controlled Microstructures: Multiscale Modeling of Direct Metal Laser Sintering and Directed Energy Deposition

Author(s):

Arjun Tekalur, Jacob Kallivayalil, Jason Carroll, Mike Killian, Benjamin Schultheis, Anil Chaudhary, Zackery B. McClelland, Jeffrey B. Allen, Jameson D. Shannon, and Robert D. Moser

Purpose/Abstract:

The report includes work conducted in a collaborative research and development program between Eaton Corporation and the U.S. Army Engineer Research and Development Center focused on novel multiscale modeling approaches to optimize metal additive manufacturing (AM) processes. The research focused on developing new lower-length scale thermal history predictions with microstructure to property relationships to computationally study a variety of manufacturing parameters and their correlation to defects generation and mechanical properties. Direct metal laser sintering (DMLS - a powder bed AM method) and directed energy deposition (DED - a blown powder AM method) were studied. The results indicated that the developed tools could rapidly predict optimal manufacturing parameters through fast running layer-by-layer thermal models of each respective AM process. Physical test specimens and prototypes were also produced as part of the study to aid in model calibration and validation through mechanical testing and microstructural characterization.

148 pgs / 37 mb

CLASSIFICATION: UNCLASSIFIED

ERDC is a diverse research organization with approximately 2,000 employees operating more than $1 billion in world class facilities at seven laboratories. Its annual program exceeds $1 billion as it supports the Department of Defense and other agencies in military and civilian projects. Principal research areas include Soldier support, Engineered Resilient Systems, Environmental Quality and Installations, Geospatial Research and Engineering, Military Engineering, and Water Resources.  “Discover ▪ Develop ▪ Deliver” ERDCinfo@usace.army.mil


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