LAUSR

Early work in finite-element analysis of additive manufacturing (AM) components was not able to include distortion and residual stress of the entire build, yielding uncertainty in the computational model predictions. To address this, current versions of recently developed computational tools are being used to understand their role in validation at the Naval Surface Warfare Center, Carderock Division, for laser powder-bed fusion (L-PBF) AM. A 316L stainless steel L-PBF build containing multiple parts, which exhibited the same local part failure over multiple AM fabrication runs, was selected for computational analysis. Single-part simulations analyzed optimization of computational speed and prediction accuracy. Full-build simulations exposed the smallest re-coater tolerances early in part fabrication as a result of part shrinkage and subsequent cupping. This cupping was predicted to change the powder spreading and result in the non-consolidation of the support structures, which paralleled the failures seen in the physical builds. Part redesign of the conventionally produced part to align with AM fabrication requirements was recommended to alleviate the build failures. This project is part of a larger program focused on validation of the computational tools to determine best practices for insertion of AM simulation into the greater Naval enterprise.