Development and verification of microstructure, residual stress and deformation simulation capability for additive free-form direct deposition using multiple superalloys

SUPERMODEL will (1) develop a state-of-the-art microstructure evolution model for blown powder laser metal deposition processing and post-processing of multiple super alloys (including Inconel 718) that can predict grain sizes; orientation and texture; phase composition (including precipitation & particle size); and defect (pores and lack of fusion) distributions; (2) link the microstructure model to part-level (global) thermo-mechanical LMD process simulations to enable a direct coupling between continuum-scale stress-strain behaviour and the evolution of microstructural internal state variables; (3) validate the computational models through iterative, detailed and comprehensive experimental test programmes including in-line monitoring of melt pools, thermal transients, stresses and deformation; post-build, 3D scanning of part distortions; metallographic examination and CT scanning; and (4) demonstrate the predictive powder of the model on a complex part (curved substrate with angular features) incorporating two different superalloys with runtimes less than 5 days. This will be achieved through an ambitious numerical-experimental procedure leveraging design-of-experiments methodologies and iterative feedback between modelling activities and testing to develop a robust software system.

SUPERMODEL contributes to the aims of the Clean Sky Engines ITD by providing experimental data and simulation tools that will enhance the reliability of additive manufacturing technology, thereby streamlining LMD part certification and qualification, minimises experimental trial-and-error along the way. SUPERMODEL will therefore make progress towards achieving the EC goal of moving from “Modelling-for-Industry” to “Modelling-by-Industry” which means shifting effort from laboratory- and RTO-centred activities to helping industry equip itself with advanced simulation tools.