Project Description
In the proposed research and development effort a suite of simulations will be used to study the high-speed impact of particle deposition on a substrate during cold and thermal spray additive manufacturing (AM) techniques. The effort will include using finite element software (e.g. Abaqus Explicit) to model the effect of various process parameters (impact angle, standoff distance, particle feed rate, gas environment, preheat temperature, etc.) on the resulting particle/substrate deformation behavior, adhesion, and coverage. Experimental R&D studies in collaboration with a local business partner will be leveraged to calibrate and validate the modeling efforts.
Tasks and Responsibilites
1) Develop pipeline for creation of parametric Abaqus input files containing single and multi-particle finite element model meshes, loading & boundary conditions versus time, and temperature-dependent equation of state and material properties/parameters. 2) Develop automated job submission script utilizing slurm/unix commands to set Mortimer HPC environment and number of cpus to use for the cold/thermal spray AM process simulations. 3) Perform optical microscopy and/or scanning electron microscopy characterization of the experimental cold/thermal spray AM specimens provided by the industrial partner. 4) Develop analysis pipeline (Python, Matlab, ImageJ, etc.) to read in and compare experimental and simulation results. 5) Develop pipeline to update material parameters for calibration/validation based on the comparison of experimental and simulation results. 6) Report research findings periodically to Academic mentor and within poster session at Undergraduate Research Symposium.