Data-Driven
Modeling for Additive
Manufacturing of Metals
PROCEEDINGS OF A WORKSHOP
Janki Patel, Rapporteur
Board on Mathematical Sciences and Analytics
National Materials and Manufacturing Board
Division on Engineering and Physical Sciences
THE NATIONAL ACADEMIES PRESS
Washington, DC
www.nap.edu
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This activity was supported by the U.S. National Institute of Standards and Technology (Contract No. SB134117CQ0017), the Department of Energy, Los Alamos National Laboratory, and Sandia National Laboratories. Any opinions, findings, conclusions, or recommendations expressed in this publication do not necessarily reflect the views of any organization or agency that provided support for the project.
International Standard Book Number-13: 978-0-309-49420-5
International Standard Book Number-10: 0-309-49420-6
Digital Object Identifier: https://doi.org/10.17226/25481
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Copyright 2019 by the National Academy of Sciences. All rights reserved.
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Suggested citation: National Academies of Sciences, Engineering, and Medicine. 2019. Data-Driven Modeling for Additive Manufacturing of Metals: Proceedings of a Workshop. Washington, DC: The National Academies Press. https://doi.org/10.17226/25481.
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PLANNING COMMITTEE ON THE WORKSHOP ON THE FRONTIERS OF MECHANISTIC DATA-DRIVEN MODELING FOR ADDITIVE MANUFACTURING
CAROLIN KÖRNER, Friedrich-Alexander Universität Erlangen-Nürnberg, Co-Chair
WING KAM LIU, Northwestern University, Co-Chair
TAHANY EL-WARDANY, United Technologies Research Center
ADE MAKINDE, General Electric Global Research Center
MUSTAFA MEGAHED, ESI Group
CELIA MERZBACHER, SRI International
NANCY REID, NAS,1 University of Toronto
JENS TELGKAMP, Airbus Operations GmbH
KAREN E. WILLCOX, University of Texas, Austin
Staff
MICHELLE SCHWALBE, Director, Board on Mathematical Sciences and Analytics, Workshop Co-Director
ERIK SVEDBERG, Senior Program Officer, National Materials and Manufacturing Board, Workshop Co-Director
BETH DOLAN, Financial Manager
JANKI PATEL, Research Associate
___________________
1 Member, National Academy of Sciences.
BOARD ON MATHEMATICAL SCIENCES AND ANALYTICS
MARK L. GREEN, University of California, Los Angeles, Chair
HÉLÈNE BARCELO, Mathematical Sciences Research Institute
JOHN R. BIRGE, NAE,1 University of Chicago
W. PETER CHERRY, NAE, Independent Consultant
DAVID S.C. CHU, Institute for Defense Analyses
RONALD R. COIFMAN, NAS,2 Yale University
JAMES (JIM) CURRY, University of Colorado, Boulder
SHAWNDRA HILL, Microsoft Research
LYDIA KAVRAKI, NAM,3 Rice University
TAMARA KOLDA, Sandia National Laboratories
JOSEPH A. LANGSAM, University of Maryland
DAVID MAIER, Portland State University
LOIS CURFMAN McINNES, Argonne National Laboratory
JILL C. PIPHER, Brown University
ELIZABETH A. THOMPSON, NAS, University of Washington
CLAIRE J. TOMLIN, NAE, University of California, Berkeley
LANCE A. WALLER, Emory University
KAREN E. WILLCOX, University of Texas, Austin
Staff
MICHELLE SCHWALBE, Director
TYLER KLOEFKORN, Program Officer
LINDA CASOLA, Associate Program Officer
ADRIANNA HARGROVE, Financial Manager
SELAM ARAIA, Program Assistant
___________________
1 Member, National Academy of Engineering.
2 Member, National Academy of Sciences.
3 Member, National Academy of Medicine.
NATIONAL MATERIALS AND MANUFACTURING BOARD
BEN WANG, Georgia Institute of Technology, Chair
THERESA KOTANCHEK, Evolved Analytics, LLC, Vice Chair
RODNEY C. ADKINS, NAE,1 IBM Corporate Strategy (Retired)
CRAIG ARNOLD, Princeton University
JIM C.I. CHANG, National Cheng Kung University, Tainan, Taiwan
THOMAS M. DONNELLAN, The Pennsylvania State University
STEPHEN R. FORREST, NAS2/NAE, University of Michigan
ERICA R.H. FUCHS, Carnegie Mellon University
DAVID C. LARBALESTIER, NAE, Florida State University
MICHAEL MAHER, Maher and Associates, LLC
ROBERT D. MILLER, NAE, IBM Almaden Research Center
EDWARD MORRIS, Consequence Consulting, LLC
NICHOLAS A. PEPPAS, NAE/NAM,3 University of Texas, Austin
TRESA M. POLLOCK, NAE, University of California, Santa Barbara
GREGORY TASSEY, University of Washington
HAYDN WADLEY, University of Virginia
STEVEN J. ZINKLE, NAE, University of Tennessee, Knoxville
Staff
JAMES LANCASTER, Director
ERIK SVEDBERG, Senior Program Officer
NEERAJ P. GORKHALY, Associate Program Officer
HEATHER LOZOWSKI, Financial Associate
BETH DOLAN, Financial Associate
AMISHA JINANDRA, Research Associate
JOSEPH PALMER, Senior Project Assistant
___________________
1 Member, National Academy of Engineering.
2 Member, National Academy of Sciences.
3 Member, National Academy of Medicine.
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Acknowledgment of Reviewers
This Proceedings of a Workshop was reviewed in draft form by individuals chosen for their diverse perspectives and technical expertise. The purpose of this independent review is to provide candid and critical comments that will assist the National Academies of Sciences, Engineering, and Medicine in making each published proceedings as sound as possible and to ensure that it meets the institutional standards for quality, objectivity, evidence, and responsiveness to the charge. The review comments and draft manuscript remain confidential to protect the integrity of the process.
We thank the following individuals for their review of this proceedings:
Bianca Maria Colosimo, Politecnico di Milano;
Joseph M. DeSimone, NAS1/NAE2/NAM,3 University of North Carolina, Chapel Hill; and
John Turner, Oak Ridge National Laboratory.
Although the reviewers listed above provided many constructive comments and suggestions, they were not asked to endorse the content of the proceedings nor did they see the final draft before its release. The
___________________
1 Member, National Academy of Sciences.
2 Member, National Academy of Engineering.
3 Member, National Academy of Medicine.
review of this proceedings was overseen by Mark C. Hersam, Northwestern University. He was responsible for making certain that an independent examination of this proceedings was carried out in accordance with the standards of the National Academies and that all review comments were carefully considered. Responsibility for the final content rests entirely with the rapporteur and the National Academies.
Contents
Organization of This Proceedings
2 PROCESS MONITORING AND CONTROL
Measurements and Modeling for Process Monitoring and Control
Measurement Science for Process Monitoring and Control
Simulations: A Chance for Knowledge-Based Improvement of Additive Manufacturing
3 MICROSTRUCTURE EVOLUTION, ALLOY DESIGN, AND PART SUITABILITY
Measurements for Additive Manufacturing of Metals
Predicting Material State and Performance of Additively Manufactured Parts
Modeling Phases of Process and Machine Design
Modeling Challenges and Opportunities at the Part Level
5 PRODUCT AND PROCESS QUALIFICATION AND CERTIFICATION
Process Qualification and Technological Validation, from Casting to Additive
6 SUMMARY OF CHALLENGES FROM SUBGROUP DISCUSSIONS AND PARTICIPANT COMMENTS
Measurements and Modeling for Process Monitoring and Control
Developing Models to Represent Microstructure Evolution, Alloy Design, and Part Suitability
Modeling Aspects of Process and Machine Design
Accelerating Product and Process Qualification and Certification