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Moser, Daniel

Publications and source records attributed to Moser, Daniel.

At least 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Multiscale Approach to Fast ModSim for Laser Processing of Metals for Future Nuclear Deterrence Environments

Predicting performance of parts produced using laser-metal processing remains an out- standing challenge. While many computational models exist, they are generally too computationally expensive to simulate the build of an engineering-scale part. This work develops a reduced order thermal model of a laser-metal system using analytical Green's function solutions to the linear heat equation, representing a step towards achieving a full part performance prediction in an "overnight" time frame. The developed model is able to calculate a thermal history for an example problem 72 times faster than a traditional FEM method. The model parameters are calibrated using a non-linear solution and microstructures and residual stresses calculated and compared to a non-linear case. The calibrated model shows promising agreement with a non-linear solution.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Multi-scale computational modeling of residual stress in selective laser melting with uncertainty quantification

Selective laser melting (SLM) is a powder-based additive manufacturing technique which creates parts by fusing together successive layers of powder with a laser. The quality of produced parts is highly dependent on the proper selection of processing parameters, requiring significant testing and experimentation to determine parameters for a given machine and material. Computational modeling could potentially be used to shorten this process by identifying parameters through simulation. However, simulating complete SLM builds is challenging due to the difference in scale between the size of the particles and laser used in the build and the size of the part produced. Often, continuum models are employed which approximate the powder as a continuous medium to avoid the need to model powder particles individually. While computationally expedient, continuum models require as inputs effective material properties for the powder which are often difficult to obtain experimentally. Building on previous works which have developed methods for estimating these effective properties along with their uncertainties through the use of detailed models, this work presents a part scale continuum model capable of predicting residual thermal stresses in an SLM build with uncertainty estimates. Model predictions are compared to experimental measurements from the literature.

42 ENGINEERING↗
DOE OSTI2018

Born Qualified Grand Challenge LDRD Final Report

This SAND report fulfills the final report requirement for the Born Qualified Grand Challenge LDRD. Born Qualified was funded from FY16-FY18 with a total budget of ~$13M over the 3 years of funding. Overall 70+ staff, Post Docs, and students supported this project over its lifetime. The driver for Born Qualified was using Additive Manufacturing (AM) to change the qualification paradigm for low volume, high value, high consequence, complex parts that are common in high-risk industries such as ND, defense, energy, aerospace, and medical. AM offers the opportunity to transform design, manufacturing, and qualification with its unique capabilities. AM is a disruptive technology, allowing the capability to simultaneously create part and material while tightly controlling and monitoring the manufacturing process at the voxel level, with the inherent flexibility and agility in printing layer-by-layer. AM enables the possibility of measuring critical material and part parameters during manufacturing, thus changing the way we collect data, assess performance, and accept or qualify parts. It provides an opportunity to shift from the current iterative design-build-test qualification paradigm using traditional manufacturing processes to design-by-predictivity where requirements are addressed concurrently and rapidly. The new qualification paradigm driven by AM provides the opportunity to predict performance probabilistically, to optimally control the manufacturing process, and to implement accelerated cycles of learning. Exploiting these capabilities to realize a new uncertainty quantification-driven qualification that is rapid, flexible, and practical is the focus of this effort.

36 MATERIALS SCIENCE↗