A Finite Element Framework for Non-linear Material Constitutive Modelling of Superalloy Additive Manufactured Parts

Due to its versatility, time and cost saving, additive manufacturing (AM) technology, and more specifically selective laser melting process (SLM), is replacing conventional manufacturing processes, particularly for producing complex geometry components. In this technology, the near net shape parts are incrementally built by fusing layers of powder material using an intensive heating source/ Structural stress analysis and lifing assessment via finite element (FE) analysis are well-accepted modern engineering practices within product development procedures. The use of this solution method reduces trial and error costs as well as risks of failure, among other. Because of the unique microstructure/texture of the additively manufactured superalloy products, the resulting mechanical properties are highly anisotropic as opposed to conventionally manufactured parts which are commonly isotropic. Consequently, efficiently predicting the mechanical properties and functional performance of SLM components through FE simulations become crucial. In this context, the main objective of this project is to create a reliable FE simulation framework for predicting operating performance of SLM manufactured gas turbine hot section components for Siemens Canada. In this research, advanced phenomenological material constitutive models for additive manufacturing applications will be identified and developed. Also, numerical predictions will be validated against experimental data.

Omid Majidi
Faculty Supervisor: 
Mathias Legrand
Partner University: