Journal
JOM
Volume 73, Issue 10, Pages 3064-3081Publisher
SPRINGER
DOI: 10.1007/s11837-021-04770-3
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Funding
- Air Force Research Laboratory [FA8650-16-2-5700]
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The study uses a feature-based qualification method to reduce the cost and time of DED process qualification. A hybrid-physics-based multi-objective optimization tool is used to predict processing-structure-property relationships in thin-walled builds. The probabilistic ML models achieved targeted predictions with higher reliability compared to conventional methods.
Additive manufacturing usually involves the complex interaction of design, materials, and manufacturing, often resulting in long and cost-intensive iterative evaluation cycles. Therefore, it is critical for it to be aligned with the Materials Genome Initiative to develop, produce, and deploy high-throughput components. Recognizing a need, this study leverages a feature-based qualification (FBQ) methodology to decompose a complex structure by identifying critical performance-limiting features, for the purpose of reducing the cost and time of DED process qualification. A hybrid-physics-based multi-objective optimization tool was used to predict processing-structure-property relationships in thin-walled builds. The probabilistic ML models achieved targeted predictions with half the sample space when compared with conventional DOEs, while also being 37-50% more reliable with respect to regression tools with linear basis function. Although the current model developed is specific to Ti64 builds in a RPMi557 powder-feed DED machine, the FBQ methodology may be more universally employed to other material-modality combinations.
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