NASA STTR 2014 Solicitation


PROPOSAL NUMBER: 14-1 T12.04-9977
RESEARCH SUBTOPIC TITLE: Experimental and Analytical Technologies for Additive Manufacturing
PROPOSAL TITLE: Multiple High-Fidelity Modeling Tools for Metal Additive Manufacturing Process Development

NAME: CFD Research Corporation NAME: University of Alabama - Tuscaloosa
STREET: 701 McMillian Way Northwest, Suite D STREET: Box 870104
CITY: Huntsville CITY: Tuscaloosa, AL
STATE/ZIP: AL  35806 - 2923 STATE/ZIP: AL  35787 - 0104
PHONE: (256) 726-4800 PHONE: (205) 348-5152

PRINCIPAL INVESTIGATOR/PROJECT MANAGER (Name, E-mail, Mail Address, City/State/Zip, Phone)
J. Vernon Cole
701 McMillian Way NW, Suite D
Huntsville, AL 35806 - 2923
(256) 726-4800

CORPORATE/BUSINESS OFFICIAL (Name, E-mail, Mail Address, City/State/Zip, Phone)
Silvia Harvey
701 McMillian Way NW, Suite D
Huntsville, AL 35806 - 2923
(256) 726-4858

Estimated Technology Readiness Level (TRL) at beginning and end of contract:
Begin: 2
End: 3

Technology Available (TAV) Subtopics
Experimental and Analytical Technologies for Additive Manufacturing is a Technology Available (TAV) subtopic that includes NASA Intellectual Property (IP). Do you plan to use the NASA IP under the award?

TECHNICAL ABSTRACT (Limit 2000 characters, approximately 200 words)
Despite the rapid commercialization of additive manufacturing technology such as selective laser melting, SLM, there are gaps in process modeling and material property prediction that contribute to slow and costly process qualification and product certification. To address these gaps, CFDRC and our partner Dr. Kevin Chou, University of Alabama, will develop multiple computationally efficient, high-fidelity simulation tools for the SLM process. During Phase I the team will apply adaptive meshing to enable efficient thermomechanical simulations for centimeter size test coupon builds, leverage existing multiphase flow models to analyze particle size effects on material variations, apply phase field models to predict microstructure evolution, and evaluate model predictions against experimental characterization. During Phase II, the modeling tools will be extended to improve computational efficiency and scalability to aerospace component dimensions by further leveraging parallel computing and other acceleration techniques. The fidelity of the models will be enhanced to better predict distortion, residual stress, microstructure and defects from process conditions; and additional process data will be used to validate the resulting codes. The resulting toolset will be capable of efficiently predicting these dimensional and microstructural properties of SLM components from process conditions, while addressing important design and build features such as overhanging sections and build supports. The high-fidelity, physics based nature of the codes will allow straightforward application to new materials, and to guiding development of and verifying analytical physics models for process control.

POTENTIAL NASA COMMERCIAL APPLICATIONS (Limit 1500 characters, approximately 150 words)
NASA has demonstrated the potential for cost and time savings via additive manufacturing, successfully building and testing a complex rocket injector. The build took 3 weeks, at half the cost of traditional methods that require 6 months. The technology also offers the potential for design flexibility, weight savings, and increased reliability from monolithic parts with reduced joining. The proposed models will allow for a deeper understanding of the resulting material properties and increase the confidence in, and use of, additive manufactured parts. Furthermore the tools will enable process control and reduced time to optimize the recipe for a given part, thereby enabling the proliferation of additive manufacturing as a rapid prototyping and production tool for components in critical NASA systems.

POTENTIAL NON-NASA COMMERCIAL APPLICATIONS (Limit 1500 characters, approximately 150 words)
Mature AM technologies will benefit designers and producers of aerospace components for military and civilian aircraft with low 'buy-to-fly' costs and increased functionality similar to the NASA benefits. Beyond the aerospace industry, there are opportunities for this technology in other high-value engineering applications such as production of patient-specific biocompatible implants.

TECHNOLOGY TAXONOMY MAPPING (NASA's technology taxonomy has been developed by the SBIR-STTR program to disseminate awareness of proposed and awarded R/R&D in the agency. It is a listing of over 100 technologies, sorted into broad categories, of interest to NASA.)
Lasers (Machining/Materials Processing)
Models & Simulations (see also Testing & Evaluation)
Software Tools (Analysis, Design)

Form Generated on 04-23-14 17:37