Develop surface and microstructural computational models of AM processing

The Déantús Advanced Manufacturing Research Centre will draw together research expertise from academia and industry to deliver innovation in additive manufacturing (AM) techniques and processes. Déantús Platform research combines novel metrology, modelling, data analytics and control theory to achieve significantly enhanced AM processing efficiency for metals and ploymers. Platform research highlights include (a) new process-structure-property models of AM, (b) novel materials, metrology and in-process data collection, (c) new technology for smart injection moulding, and (d) the application of novel cognitive computing methods to data interpretation and decision support for AM equipment operators.

Platform 2, Process-Structure Modelling, will develop and validate new models for the simulation of powder flow, metal melting, melt flow, metal solidification, and microstructure evolution, as well as constitutive models of resulting mechanical properties. In Platform 2, models of powder flow, melt flow, and solidification will combine discrete element modelling, continuum two-phase flow computational fluid dynamics, and plasticity models. To predict microstructure formation and identify columnar-equiaxed transitions, cellular automata (CA) will be applied for front tracking (FT). To couple the fluid solidification and microstructure evolution processes, a common software architecture OpenFOAM will be utilised. For mechanical property prediction, the phase field method (PFM) will be used, in combination with strain gradient crystal plasticity finite element models. Platform 2 will deliver a process-structure¬property through process model for the first time.

Project description: Develop surface and microstructural computational models of AM process
Develop models of surface melting of powders and free surface of molten alloy using Smoothed Particle Hydrodynamics formulation. Develop model of nucleation of solid and high resolution microstructural evolution using Phase Field methods. Coupling of length scales to meso-scale models of solidification and CFD. Simulations of surface and microstructural evolution using the new models.