PREDICTIVE THEORETICAL AND
COMPUTATIONAL APPROACHES FOR
ADDITIVE MANUFACTURING

Proceedings of a Workshop

Michelle Schwalbe, Rapporteur

U.S. National Committee on Theoretical and Applied Mechanics
Board on International Scientific Organizations
Policy and Global Affairs

THE NATIONAL ACADEMIES PRESS
Washington, DC
www.nap.edu

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This workshop was supported by Grant No. CMMI-1545752 from the National Science Foundation. The Proceedings of a Workshop was supported by Grant No. 60NANB15D281 from the National Institute of Standards and Technology and Grant No. DE-AC04-94AL85000 from Sandia National Laboratories. Any opinions expressed in this publication are those of the rapporteur and do not necessarily reflect the views of any organization or agency that provided support for the project.

International Standard Book Number 13: 978-0-309-44975-5
International Standard Book Number 10: 0-309-44975-8
Digital Object Identifier: 10.17226/23646

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Suggested citation: National Academies of Sciences, Engineering, and Medicine. 2016. Predictive Theoretical and Computational Approaches for Additive Manufacturing: Proceedings of a Workshop. Washington, DC: the National Academies Press. doi: 10.17226/23646.

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PLANNING COMMITTEE ON PREDICTIVE THEORETICAL AND COMPUTATIONAL APPROACHES FOR ADDITIVE MANUFACTURING

WING KAM LIU (Chair), Northwestern University

ELIZABETH CANTWELL, Arizona State University

ANTHONY DeCARMINE, Oxford Performance Materials

SLADE GARDNER, Lockheed Martin Space Systems Company

THOMAS KURFESS, Georgia Institute of Technology

EDWARD MORRIS, National Center for Defense Manufacturing and Machining

Staff

ANA M. FERRERAS, Senior Program Officer

PAMELA GAMBLE, Administrative Associate

U.S. NATIONAL COMMITTEE FOR THEORETICAL AND APPLIED MECHANICS

Officers

WING KAM LIU (Chair), Northwestern University

GARETH H. MCKINLEY (Vice Chair), Massachusetts Institute of Technology

LINDA P. FRANZONI (Secretary), Duke University

STELIOS KYRIAKIDES (Past Chair), NAE,¹ University of Texas at Austin

Members-at-Large

JOHN DABIRI, Stanford University

ANN KARAGOZIAN, University of California, Los Angeles

CHAD LANDIS, The University of Texas at Austin

THOMAS J. PENCE, Michigan State University

Society Representatives

ACOUSTICAL SOCIETY OF AMERICA (ASA), Linda Franzoni, Duke University

AMERICAN ACADEMY OF MECHANICS (AAM), Chad Landis, The University of Texas at Austin

AMERICAN INSTITUTE OF CHEMICAL ENGINEERS (AIChE), Paul Steen, Cornell University

AMERICAN MATHEMATICAL SOCIETY (AMS), Eitan Tadmor, University of Maryland, College Park

AMERICAN PHYSICAL SOCIETY (APS), Beverley McKeon, California Institute of Technology

AMERICAN SOCIETY OF CIVIL ENGINEERS (ASCE), Roger Ghanem, University of Southern California

AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME), Nadine Aubry, NAE, Northeastern University

ASTM INTERNATIONAL (formerly American Society for Testing and Materials), Steven Daniewicz, Mississippi State University

___________________

¹ The National Academy of Engineering.

SOCIETY FOR EXPERIMENTAL MECHANICS (SEM), Wendy Crone, University of Wisconsin, Madison

SOCIETY FOR INDUSTRIAL AND APPLIED MATHEMATICS (SIAM), Qiang Du, Columbia University

SOCIETY OF ENGINEERING SCIENCE (SES), Horacio D. Espinosa, Northwestern University

SOCIETY OF ENGINEERING SCIENCE (SES), Kyung-Suk Kim, Brown University

SOCIETY OF RHEOLOGY (SOR), Eric S.G. Shaqfeh, NAE, Stanford University

UNITED STATES ASSOCIATION FOR COMPUTATIONAL MECHANICS (USACM), Tarek Zohdi, University of California, Berkeley

Ex Officio Members

JIANMIN QU, Tufts University

Staff

ANA M. FERRERAS, Senior Program Officer

PAMELA GAMBLE, Administrative Associate

BOARD ON INTERNATIONAL SCIENTIFIC ORGANIZATIONS

Members

MICHAEL CLEGG (Chair), NAS,¹ University of California, Irvine

PATRICK SCOTT (Vice Chair), Los Alamos National Laboratory Foundation

ALLAN C. ASHWORTH, North Dakota State University

ASMERET ASEFAW BERHE, University of California, Merced

MELODY BROWN BURKINS, Dartmouth College

RONALD GRAHAM, NAS, University of California, San Diego

MARVIN HACKERT, University of Texas at Austin

KENNETH KELLERMANN, NAS, National Radio Astronomy Observatory

WING KAM LIU, Northwestern University

C. BRADLEY MOORE, NAS, University of California, Berkeley

KENNEDY REED, Lawrence Livermore National Laboratory

DONALD SAARI, NAS, University of California, Irvine

JEFFREY ZACKS, Washington University in St. Louis

Ex Officio Members

JOHN HILDEBRAND, NAS, University of Arizona, Tucson

MICHAEL CLEGG (Chair), NAS,² University of California, Irvine

Staff

KATHIE BAILEY, Director

ESTER SZTEIN, Assistant Director and Senior Program Officer

ANA M. FERRERAS, Senior Program Officer

LOIS PETERSON KENT, Senior Program Officer

PAMELA GAMBLE, Administrative Associate

CHELSEA BOCK, Program Coordinator

___________________

¹ The National Academy of Sciences.

² The National Academy of Sciences.

Acknowledgments

We would like to thank the following staff members for their contributions to this report: Ana Ferreras, Senior Program Officer; Michelle K. Schwalbe, Senior Program Officer; Aqila A. Coulhurst, Associate Program Officer; and Linda Casola, Staff Editor.

REVIEWERS

This report has been reviewed in draft form by individuals chosen for their diverse perspectives and technical expertise, in accordance with procedures approved by the National Academies of Sciences, Engineering, and Medicine’s Report Review Committee. The purpose of this independent review is to provide candid and critical comments that will assist the institution in making its published report as sound as possible and to ensure that the report meets institutional standards for quality and objectivity. The review comments and draft manuscript remain confidential to protect the integrity of the process.

We wish to thank the following individuals for their review of this report: Michael Gorelik, Federal Aviation Administration; Lonnie Love, Oak Ridge National Laboratory; Amit Misra, University of Michigan; Edwin Schwalbach, Air Force Research Laboratory; and Tarek Zohdi, University of California, Berkeley.

Although the reviewers listed above have provided many constructive comments and suggestions, they were not asked to endorse the content of

the report, nor did they see the final draft before its release. The review of this report was overseen by Robert Schafrik (Retired), General Electric Aviation. Appointed by the National Academies, he was responsible for making certain that an independent examination of this report was carried out in accordance with institutional procedures and that all review comments were carefully considered. Responsibility for the final content of this report rests entirely with the rapporteur and the institution.

Wing Kam Liu
Chair, Planning Committee

Contents

1 INTRODUCTION

Workshop Overview

Organization of This Report

2 THEORETICAL UNDERSTANDING OF MATERIALS SCIENCE AND MECHANICS

Toward Modeling and Simulations of Additive Manufacturing of Metals at Los Alamos National Laboratory

Challenges in Additive Manufacturing of Soft Materials: Polymer-based Fused Deposition Modeling

Modeling and Simulations of Additive Manufacturing

Discussion

Theoretical Understanding of Materials Science and Mechanics

Part-Level Finite Element Simulation of Selective Laser Melting

Main Physical Phenomena in Metal Powder-Bed Fusion

Discussion

3 COMPUTATIONAL AND ANALYTICAL METHODS IN ADDITIVE MANUFACTURING

Computational and Analytical Needs in Additive Manufacturing

High-Performance Computing and Additive Manufacturing: Overcoming the Barriers to Material Qualification

Revolutions in Design and Manufacturing: Topology Optimization and Uncertainty Quantification in Additive Manufacturing

Discussion

Application of Integrated Computational Materials Engineering to the Design and Development of New High-Performance Materials for Additive Manufacturing

Computational and Analytical Methods in Additive Manufacturing: Linking Process to Microstructure

Additive Manufacturing Challenges for Computational Solid Mechanics

Discussion

4 MONITORING AND ADVANCED DIAGNOSTICS TO ENABLE ADDITIVE MANUFACTURING FUNDAMENTAL UNDERSTANDING

Process Modeling and Diagnostic Considerations

Barriers to Widespread Additive Manufacturing

Directed Energy Deposition and Electrospinning

Discussion

Enhancing End-User Control

Analysis of Highly Correlated Data Sets to Establish Processing-Structure-Property Relationships for Additively-Manufactured Metals

In-Process Sensing of Laser Powder-Bed Fusion Additive Manufacturing

Discussion

5 ADDITIVE MANUFACTURING SCALABILITY, IMPLEMENTATION, READINESS, AND TRANSITION

Additive Manufacturing: Capabilities, Challenges, and the Future

Software Architecture, Database Development, and Model Validation: Toward a Computational Benchmark in Additive Manufacturing

A Different Perspective on Scalability and Public-Private Partnership

Discussion

Scalability, Implementation, Readiness, and Transition

Testing, Accuracy, and Beyond

Computational Simulation and Advanced Optimization: The Key Role of Public-Private Partnerships in Scalability

Discussion

6 SUMMARY OF ISSUES FROM SUBGROUP DISCUSSIONS

Theoretical Understanding of Materials Science and Mechanics

Computational and Analytical Methods in Additive Manufacturing

Monitoring and Advanced Diagnostics to Enable AM Fundamental Understanding

REFERENCES

APPENDIXES

A Registered Workshop Participants

B Workshop Agenda

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