| About this Abstract |
| Meeting |
2024 AWS Professional Program
|
| Symposium
|
2024 AWS Professional Program
|
| Presentation Title |
Process-Microstructure-Property Computational Optimization of AF9628 Wire-Arc Directed Energy Deposition Additive Manufacturing |
| Author(s) |
Nikolas Maximiliano Vega Michalak, Boian Alexandrov, Philip Flater, Dennis Harwig, Logan McNeil |
| On-Site Speaker (Planned) |
Nikolas Maximiliano Vega Michalak |
| Abstract Scope |
AF9628 is a low alloy steel with a good balance of strength, hardness, toughness, and affordability. Performance optimization in the large format metal additive manufacturing (MAM) of AF9628 is required to take advantage of increasingly complex mechanical component design. Conventional AM parameter development for a new material uses a trial-and-error approach that is time, material, and labor intensive and therefore cost-prohibitive. This work aims to optimize process-microstructure-properties (PMP) of wire-arc directed energy deposition (WA-DED) of AF9628 through a computational design of experiments (CDoE) framework. The CDoE framework integrates a design of experiments (DoE), finite element analysis (FEA), thermodynamic and kinetic modeling, and post processing modules to achieve this objective. The CDoE framework will be validated through comparison of simulated results to physical AF9628 WA-DED builds. Specifically, work will be done to produce simulated thermal histories that match in-situ measured thermal histories of AF9628 WA-DED. Thermal histories will be matched by calibrating the simulated heat source to measured fusion boundary profiles of AF9628 WA-DED as well as continued development of the FEA module to match all WA-DED process variables. Further validation will occur through predicting matching microstructure and hardness of simulated builds to physical AF9628 WA-DED builds. Prediction of microstructure and hardness will be done through the post processing module which applies previously developed PMP relationships consisting of an AF9628 WA-DED continuous cooling transformation (CCT) diagram and hardness-tempering response relationships. Once validated, the CDoE framework will be used to find optimal PMP parameter windows of AF9628 WA-DED. Optimal PMP windows are determined by comparing predicted microstructure and hardness to predetermined property criteria. Optimization will be demonstrated through production and testing of AF9628 WA-DED builds using optimal PMP parameter windows. |
| Proceedings Inclusion? |
Undecided |