University of Pittsburgh engineers have received grants to develop modeling and simulation technologies and standard qualification methods for additive manufacturing (AM), which is widely known as 3D printing.
AM enables production of metal components with complex structures having distinctive lattice geometries. However, the quality standards required for testing as well as the modeling processes used have not kept up with the advances in technology.
The Pennsylvania Department of Community and Economic Development and America Makes have awarded $150,000 as a Research for Additive Manufacturing in Pennsylvania (RAMP) grant for the "Automation Tools for Modeling AM Process of Complex Geometries in ABAQUS" project. The National Science Foundation's Division of Civil, Mechanical and Manufacturing Innovation has awarded a $300,000 grant for the project titled "Multiscale Structure-Mechanical Property Investigation of Additive Manufactured Components for Development of a Reliable Qualification Method."
An associate professor of mechanical engineering and materials science at the University of Pittsburgh's Swanson School of Engineering, Albert To, is the principal investigator for both the projects. An assistant professor of mechanical engineering and materials science, Markus Chmielus; and associate dean for international initiatives and dean of the Sichuan University – Pittsburgh Institute, and Mary Orr Chair professor of materials science and mechanical engineering, Minking K. Chyu, are the co-PIs for the project.
Complex structures that are difficult to produce using "subtractive" manufacturing can be manufactured through 3D printing. However, the modeling processes for such structures are error-prone as they take up a lot of time. As part of the grant, the finite element simulation of some 3D printing processes and materials will initially be automated by developing computer codes. Further, enhancing these models would help design the process and the geometry of the parts so as to reduce the residual stress that may cause the part to fail during production.
Better knowledge of the mechanical behavior and the microstructure of the components are required in order to develop new qualification standards. These are essential for ascertaining the integrity, safety and viability of the qualification methods. The investigators will use mechanical testing, computer simulation, and X-ray micro computerized tomography for analyzing the effects of residual stress and defects. This will aid in developing a fast, non-destructive, cost-effective, dependable, computer-based method for enhancing techniques and quality of 3D printing.
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