An integrated (ICME) approach to multiscale modelling of the fabrication and joining of powder processed parts

对粉末加工零件的制造和连接进行多尺度建模的集成 (ICME) 方法

• 批准号: EP/P005284/1
• 负责人: Hector Basoalto
• 金额: $ 127.87万
• 依托单位: University of Birmingham
• 依托单位国家: 英国
• 项目类别: Research Grant
• 财政年份: 2016
• 资助国家: 英国
• 起止时间: 2016 至 无数据
• 项目状态: 已结题
• 来源: https://gtr.ukri.org/projects?ref=EP%2FP005284%2F1
• 关键词: integrated; ICME; approach; multiscale; modelling

The applicability of metallic powder based production methods such as HIP or additive layer manufacturing (ALM) are restricted by an inability to define the process parameters with sufficient accuracy to provide the quality required for industrial production. Similarly the implementation of the joining technologies needed for component fabrication is limited by a lack of understanding of both the gas-liquid phase interactions and the effect of the solid state phase transformations that occur in the relevant alloy systems. Traditional solutions, based on practical trials and physical assessment, are both costly and time consuming and for the long service lives encountered in the energy and propulsion industries are not feasible while empirically based phenomenological modelling approaches cannot provide the required fidelity. To address these industrial needs a multiscale modelling approach is proposed which combines experimental validation with the application of materials modelling, at the short length scales required to capture the relevant physics, together with the development of techniques to incorporate the predicted behaviour in a consistent manner at higher length scales for application to component level simulations. The multiscale model integration will consist of a number of component parts commencing with new multiphysics based computational fluid dynamics calculations of the short length scale fluid flow and liquid/gas interactions in welding and additive manufacturing. These will provide data on porosity formation which will be combined with cellular automata predictions of grain structure. Novel methods will be developed to combine this fine scale data in a finite element based crystal plasticity framework to define representative volume elements for modelling the macroscopic behaviour in component stress analysis.The component level simulation work will build upon the EPSRC Manufacturing Fellowship of Prof Smith on a whole-life approach to high integrity welding technologies by utilising the knowledge gained on the effect of the microstructural changes imposed by welding. These have a profound influence on a weld's resistance to in-service degradation and upon its sensitivity to the presence of cracking. The microstructural characterisation data available on 316L stainess steel from the Fellowship work will also provide a basis for the model validation.A key part of the developments in this project will be the extension, from typical single value deterministic models, to statistically based descriptions of material properties and process variability. This is a challenging activity but it is essential that modelling tools become capable of predicting the scatter that is seen in real materials. A successful solution will not only generate novel science but will clearly lead to the development of probabilistic lifing methods with risk based outputs for decision making which have clear benefits for industry. This approach provides the prospect of a better understanding of in-service performance of components and welds in both the existing UK nuclear reactor fleet and in any industrial sector where long term structural performance is important.Similar developments in the US have led to a new field known as Integrated Computational Materials Engineering (ICME). This is a multi-disciplinary approach to product design that offers huge economic potential and the successful implementation of ICME will revolutionise the way components are being designed and manufactured. This proposal will address the modelling and design challenge using an ICME based approach on industrial demonstrators of 316L stainless steel HIPped and TIG welded parts. The demonstrators, supplied by the partners from the aerospace and energy industries, will show the benefits that can be achieved in different market sectors. The proposed programme will be the first attempt in the UK to use ICME tools on large industrial scale demonstrators.

基于金属粉末的生产方法（例如髋关节或添加剂层制造（ALM））的适用性受到无法以足够精确的方式定义工艺参数以提供工业生产所需的质量的限制。同样，组件制造所需的连接技术的实施受到对气体液相互作用的了解以及相关合金系统中发生的固态相变的影响的限制。基于实际试验和物理评估的传统解决方案既昂贵又耗时，对于能源和推进行业遇到的长期服务生活是不可行的，而基于经验的现象学建模方法不能提供所需的忠诚度。为了满足这些工业需求，提出了一种多尺度建模方法，该方法将实验验证与材料建模的应用结合在一起，以捕获相关物理所需的短长度尺度，以及开发技术以在较高的长度尺度用于应用到组件级模拟。多尺度模型集成将由许多组件零件组成，这些零件是从新的多物理学开始的，基于新的多物理学的计算流体动力学计算，对焊接和添加剂制造中的短长度尺度流体流量以及液体/气体相互作用。这些将提供有关孔隙率形成的数据，该数据将与晶粒结构的细胞自动机预测相结合。将开发新的方法来将此精细的数据结合在有限元的基于有限元的晶体可塑性框架中，以定义代表性的体积元素，以建模组件应力分析中的宏观行为。通过利用焊接对微观结构变化的影响而获得的知识，一种全寿命的方法。这些对焊缝对在职降解的抵抗以及对裂纹存在的敏感性具有深远的影响。来自奖学金工作的316L污渍钢上可用的微观结构表征数据也将为模型验证提供基础。该项目中的开发的关键部分将是扩展，从典型的单个值确定性模型到基于统计的材料描述属性和过程可变性。这是一项具有挑战性的活动，但是必须能够建模工具能够预测实际材料中看到的散射。成功的解决方案不仅会产生新颖的科学，而且会显然导致开发具有基于风险的决策产量的概率的实现方法，这些方法对行业具有明显的好处。这种方法可以更好地了解现有的英国核反应堆机队的组件和焊缝的在职式性能，以及在长期结构表现很重要的任何工业领域。称为集成计算材料工程（ICME）。这是一种多学科产品设计的方法，具有巨大的经济潜力，成功实施ICME将彻底改变组件的设计和制造方式。该提案将使用基于ICME的工业示威者的316升不锈钢和TIG焊接零件的工业示威者的方法来应对建模和设计挑战。由航空航天和能源行业的合作伙伴提供的示威者将显示在不同市场部门可以实现的好处。拟议的计划将是英国首次尝试在大型工业规模演示者上使用ICME工具的尝试。

项目成果

A thermal fluid dynamics framework applied to multi-component substrates experiencing fusion and vaporisation state transitions

• DOI: 10.1038/s42005-020-00462-7
• 发表时间: 2020-11-03
• 期刊: COMMUNICATIONS PHYSICS
• 影响因子: 5.5
• 作者: Flint, Thomas F.;Scotti, Lucia;Smith, Michael C.
• 通讯作者: Smith, Michael C.

An assessment of statistical models of competitive growth during transient Ostwald ripening in turbine disc nickel-based superalloys

• DOI: 10.1088/1361-651x/ac8c5d
• 发表时间: 2022-08
• 期刊: Modelling and Simulation in Materials Science and Engineering
• 影响因子: 1.8
• 作者: M. Anderson;L. Liao;H. Basoalto

Prediction of grain structure evolution during rapid solidification of high energy density beam induced re-melting

高能量密度束诱导重熔快速凝固过程中晶粒结构演化的预测

• DOI: 10.1016/j.matdes.2018.03.036
• 发表时间: 2018
• 期刊: Materials & Design
• 影响因子: 8.4
• 作者: Flint T

Phase-Field Simulation of Grain Boundary Evolution In Microstructures Containing Second-Phase Particles with Heterogeneous Thermal Properties

• DOI: 10.1038/s41598-019-54883-8
• 发表时间: 2019-12
• 期刊: Scientific Reports
• 影响因子: 4.6
• 作者: T. Flint;Y. Sun;Q. Xiong;M. Smith;J. Francis

Keyhole formation and thermal fluid flow-induced porosity during laser fusion welding in titanium alloys: Experimental and modelling

• DOI: 10.1016/j.actamat.2016.12.062
• 发表时间: 2017-03-01
• 期刊: ACTA MATERIALIA
• 影响因子: 9.4
• 作者: Panwisawas, Chinnapat;Perumal, Bama;Basoalto, Hector C.
• 通讯作者: Basoalto, Hector C.