Probabilistic Integration of Material Process Modeling and Fracture Risk Assessment Using Gaussian Process Models

Enright, Michael P.; McFarland, John; McClung, R. Craig; Wu, Wei‐Tsu; Shankar, Ravi

doi:10.2514/6.2013-1851

Cited by 6 publications

(3 citation statements)

References 18 publications

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“…The solution temperature was set at the deterministic values associated with the selected experiment data, whereas GED was not an input variable in this model. A Gaussian process [4] response surface was used as a surrogate model in order to carry out the calibration analysis.…”

Section: Discussionmentioning

confidence: 99%

Towards rapid qualification of powder-bed laser additively manufactured parts

Peralta

Enright

Megahed

et al. 2016

Integr Mater Manuf Innov

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Qualification of aerospace components is a long and costly process involving material properties, material specifications, manufacturing process, and design among others. Reducing qualification time and cost while maintaining safety offers a large economic advantage and enables faster response to the market demands. In 2012, DARPA established the Open Manufacturing program, a project to develop an integrated computational materials engineering (ICME) framework aimed at rapid qualification. Rapid qualification requires the integration of several technologies: materials, process, design, models, monitoring and control, non-destructive evaluation (NDE), testing, among others. A probabilistic design approach is adopted in the rapid qualification process to enable the integration of these technologies into a single risk-based function to optimize the design process. This approach directs the efforts to those areas that play the most important roles, potentially reducing specimen testing that will be required to develop material databases and design limits. New tests also will be required to validate and verify the ICME framework and develop a better understanding of the processing-microstructure-property relation and associated variability of the processing conditions. The probabilistic design approach is demonstrated for the rapid qualification of an actual aircraft engine component constructed via the powder-bed additive manufacturing process. This paper summarizes the probabilistic rapid qualification design approach and its application to this novel manufacturing process with the goal of reducing the overall qualification process time by 40 % and qualification process cost by 20 %.

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Section: Discussionmentioning

confidence: 99%

Towards rapid qualification of powder-bed laser additively manufactured parts

Peralta

Enright

Megahed

et al. 2016

Integr Mater Manuf Innov

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“…The manufacturing process simulation introduces additional opportunities for probabilistic analysis, since the DEFORM outputs (microstructure or RS) can themselves have variability driven by variability in DEFORM input parameters (manufacturing process model parameters). A probabilistic framework [4] has been developed to incorporate DEFORM calculations of random RS into the fracture risk computations. A combined technique of Principal Components Analysis and Gaussian Process modeling was used to estimate the relationship among model responses and material processing parameters.…”

Section: Component Stress Contours (Ksi)mentioning

confidence: 99%

Integrating Fatigue Crack Growth into Reliability Analysis and Computational Materials Design

McClung

Enright

Moody

et al. 2014

AMR

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Recently a new methodology was developed for automated fatigue crack growth (FCG) life analysis of components based on finite element stress models, weight function stress intensity factor solutions, and algorithms to define idealized fracture geometry models. This paper describes how the new methodology is being used to integrate FCG analysis into highly automated design assessments of component life and reliability. In one application, the FCG model automation is supporting automated calculation of fracture risk due to inherent material anomalies that can occur anywhere in the volume of the component. Automated schemes were developed to divide the component into a computationally optimum number of sub-volumes with similar life and risk values to determine total component reliability accurately and efficiently. In another application, the FCG model automation is supporting integration of FCG life calculations with manufacturing process simulation to perform integrated computational materials engineering. Calculation of full-field, location-specific residual stresses or microstructure is being linked directly with automated life analysis to determine the impact of manufacturing parameters on component reliability.

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“…Some of these features may be at the macro-scale (macro-texture), meso-scale (grain flow), micro-scale (grain, precipitate and defect structures) and atomistic-scale (grain boundary elemental segregation or compositionally dependent anti-phase boundary (APB) energies) [18][19][20]. Location-specific design and manufacturing control can and is being linked with probabilistic lifing tools and component application-level predictions [21]. The ability and application of linking MBMDs and component design discipline tools and methods will enable maximized use of material capabilities and optimal component designs and performance.…”

Section: Employing a Model-based Approach Models For Materials And Commentioning

confidence: 99%

Making the Case for a Model-Based Definition of Engineering Materials

Furrer

Dimiduk²,

Cotton

et al. 2017

Integr Mater Manuf Innov

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For over 100 years, designers of aerospace components have used simple requirement-based material and process specifications. The associated standards, product control documents, and testing data provided a certifiable material definition, so as to minimize risk and simplify procurement of materials during the design, manufacture, and operation of engineered systems, such as aerospace platforms. These material definition tools have been assembled to ensure components meet design definitions and design intent. They must ensure the material used meets "equivalency" to that used in the design process. Although remarkably effective, such traditional materials definitions are increasingly becoming the limiting challenge for materials, design, and manufacturing engineers supporting modern, model-based engineering. Demands for cost-effective, higher performance aerospace systems are driving new approaches for multi-disciplinary design optimization methods that are not easily supportable via traditional representations of materials information. Furthermore, property design values having the definitions based on statistical distributions from testing results can leave substantial margin or material capability underutilized, depending on component complexity and the application. Those historical statistical approaches based on macroscopic testing inhibit innovative approaches for enhancing materials definitions for greater performance in design. This can include location-specific properties, hybrid materials, and additively manufactured components. Development and adoption of digital and model-based means of representing engineering materials, within a design environment, is essential to span the widening gap between materials engineering and design. We believe that the traditional approach to defining materials by chemistry ranges, manufacturing process ranges, and static mechanical property minima will migrate to model-based material definitions (MBMDs), due to the many benefits that result from this new capability. This paper reviews aspects of the challenges and opportunities of model-based engineering and model-based definitions.Keywords ICME · MGI · Model-based engineering · Model-based definition · Model-based material definition · Digital engineering · Materials specifications · Representative volume elements · SERVEs

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Probabilistic Integration of Material Process Modeling and Fracture Risk Assessment Using Gaussian Process Models

Cited by 6 publications

References 18 publications

Towards rapid qualification of powder-bed laser additively manufactured parts

Towards rapid qualification of powder-bed laser additively manufactured parts

Integrating Fatigue Crack Growth into Reliability Analysis and Computational Materials Design

Making the Case for a Model-Based Definition of Engineering Materials

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