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Joshua M. Fody

Publications and source records attributed to Joshua M. Fody.

Efficient Calibration of Expensive Computational Models

Accounting for uncertainty when calibrating expensive computational models is a common challenge faced by scientists and engineers. Often Bayesian techniques are adopted to estimate a probability density function over the model parameters given noisy empirical data. The methods used to perform this type of probabilistic calibration are computationally prohibitive in that they require a large number of evaluations of the expensive model. In these cases, surrogate modeling -- that is, using a fast-to-evaluate, lower fidelity stand-in for the original computational model -- may be the only option to alleviate this computational burden. However, the upfront cost of generating training data to build a surrogate model can itself be expensive. As such, it is important to be judicious when selecting training points at which the full-fidelity model is evaluated. Here, an active learning approach is proposed that enables efficient selection of training points using approximate samples of the calibrated parameter probability density function. In this way, the training points can be concentrated in regions where the calibration algorithm requires high model accuracy.

active learning

Modeling Pore Closure in the Hot Isostatic Pressing of Additively Manufactured Inconel 718 Samples

Additive manufacturing provides opportunity for a new world of possibilities for metallic component design and fabrication; however, as-built part quality is notoriously variable, anisotropic, and degraded by porous defects. To improve quality, parts are commonly post processed using a variety of techniques including hot isostatic pressing (HIP). During HIP, high temperature and pressure is employed to improve microstructure and reduce pore volume by inducing visco-plastic deformation in the metallic substrate. Validated computational capabilities can provide predictions to guide the selection of processing condition, expected pore reduction, and the effects of varying entrapped gas in the pores. This discussion describes a micro-scale finite element structural model developed to predict pore closure due to HIP in as-built additively manufactured Inconel 718 samples produced by the laser powder bed fusion process. The model accounts for plastic deformation, creep, and internal pressure for a single pore. Pores are characterized in physical samples before and after HIP, and model predictions are compared to this measured data.

defect model prediction

Comparison of In-situ Near Infrared Melt Pool Imagery to Optical Microscopy Measurements

Additive manufacturing (AM) is a rapidly growing technology. An area of major importance is the integrity and repeatability of AM parts. The goal is to reduce obstacles to certify AM built parts to allow for use in critical aerospace applications. In-situ nondestructive evaluation sensors can be used for build assessment and can potentially play a key role in certifying AM parts. For example, melt pool features are understood to have a strong correlation to microstructural defects and the use of a near infrared (NIR) camera can be used to record the melt pool, cooling areas, and temperature gradients during the build. This work explores the use of a low cost NIR camera to obtain single line track imagery of the Ti-6Al-4V melt pools for various processing parameters. The NIR camera is radiometrically calibrated and configured in-line with the laser source to obtain high resolution imagery of the melt pool shape and dynamics. The challenge to measure melt pool shapes is to identify the transition points between the metal solid to liquid phase. Factors for melt pool measurements such as thermal camera pixel resolution, surface emissivity, and blurring due to the laser beam movement are discussed. Lastly, the melt pool imagery are compared to optical microscopy measurements for validation.

additive manufacturing